Polymeric material for container

ABSTRACT

A formulation for producing a polymeric material including high-density polyethylene, a chemical blowing agent, and other optional components is described.

PRIORITY CLAIM

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Application Ser. No. 61/845,760, filed Jul. 12, 2013, andU.S. Provisional Application Ser. No. 61/869,830, filed Aug. 26, 2013,both of which are expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to polymeric materials that can be formedto produce a container, and in particular, polymeric materials thatinsulate. More particularly, the present disclosure relates topolymer-based formulations that can produce an insulated non-aromaticpolymeric material.

SUMMARY

According to the present disclosure, a polymeric material includes apolymeric resin and at least one cell-forming agent. In illustrativeembodiments, a blend of polymeric resins and cell-forming agents ismixed and extruded or otherwise formed to produce an insulatednon-aromatic polymeric material. The insulated non-aromatic polymericmaterial has a low density but is resistant to and/or can withstandimpact forces. The low density, insulated, non-aromatic polymericmaterial provide for improved containers.

In illustrative embodiments, an insulative cellular non-aromaticpolymeric material comprises a cell-forming agent and at least onehigh-density polyethylene-based base resin. The cell-forming agent caninclude a chemical nucleating agent and a physical blowing agent. In anembodiment, a base resin can be HDPE, which can be virgin HDPE, regrind,or mixtures thereof.

In illustrative embodiments, the insulative cellular non-aromaticpolymeric material has a density of less than about 0.9 grams per cubiccentimeter. In illustrative embodiments, the insulative cellularnon-aromatic polymeric material has a density in a range of about 0.4grams per cubic centimeter to about 0.9 grams per cubic centimeter. Inillustrative embodiments, the insulative cellular non-aromatic polymericmaterial has a density in a range of about 0.5 grams per cubiccentimeter to about 0.75 grams per cubic centimeter.

In illustrative embodiments, a polyethylene-based formulation inaccordance with the present disclosure is heated and extruded to producea tubular extrudate (in an extrusion process) that can be formed toprovide a strip of insulative cellular non-aromatic polymeric material.A physical blowing agent in the form of an inert gas is introduced intoa molten material before the tubular extrudate is formed. In anillustrative embodiment, a throughput system includes a multi-parisondrop. For example, an extrusion line starts as a single line and thensplits into 2, 3, 4, 5, or more lines for multiple parison drops. Inillustrative embodiments, an insulative cellular non-aromatic polymericmaterial produced in accordance with the present disclosure can beformed to produce an insulative cup or container. Polyethylene resin isused to form the insulative cellular non-aromatic polymeric material inillustrative embodiments.

Additional features of the present disclosure will become apparent tothose skilled in the art upon consideration of illustrative embodimentsexemplifying the best mode of carrying out the disclosure as presentlyperceived.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an unassembled density determinationapparatus showing the components (clockwise starting in the upper left)gem holder, platform, suspension bracket, and suspension spacer.

DETAILED DESCRIPTION

According to the present disclosure, a polymeric material is described.The polymeric material includes at least one cell-forming agent and apolymeric resin (i.e., a thermoplastic polyolefin). In illustrativeembodiments, a blend of polymeric resins and cell-forming agents ismixed and extruded or otherwise formed to produce an insulatednon-aromatic polymeric material. The insulated non-aromatic polymericmaterial has applications for forming containers (e.g., cups andbottles).

In one exemplary embodiment, a polymer-based formulation used to producethe insulative cellular non-aromatic polymeric material includes atleast one polymeric resin. The polymeric material may include one ormore base resins. As an example, the insulative cellular non-aromaticpolymeric material comprises at least one polyethylene base resin andone or more cell-forming agents.

In one example, the base resin is high-density polyethylene (HDPE). AHDPE base resin can be a HDPE homopolymer or a HDPE copolymer. Inanother example, the base resin is a unimodal HDPE. In yet anotherexample, the base resin is unimodal, high-melt strength HDPE. In stillyet another example, the base resin is unimodal, high-melt strength HDPEsuch as DOW® DOWLEX™ IP 41 HDPE (available from The Dow ChemicalCompany) that has been electron-beam modified to provide long-chainbranching and a melt index of about 0.25 g/10 min. Another example of aunimodal, high-melt strength HDPE is EQUISTAR® ALATHON® H5520 HDPEcopolymer (available from Lyondell Chemical Company) that has beenelectron-beam modified to have long-chain branching and a melt index ofabout 0.25 g/10 min. Another example of a suitable unimodal HDPE isFORMOLENE® HB5502F HDPE hexene copolymer (available from FormosaPlastics Corporation). In another suitable embodiment of a HDPE hexenecopolymer, the HDPE is Marlex® HHM 5502BN HDPE hexene copolymer (ChevronPhillips Chemical Company, The Woodlands, Tex.).

Long-chain branching refers to the presence of polymer side chains(branches) that have a length that is comparable or greater than alength of the backbone which is coupled to the polymer side chains.Long-chain branching creates viscoelastic chain entanglements (polymerentanglements) that hamper flow during extensional or orientedstretching and provide for a strain hardening phenomenon.

The strain hardening phenomenon may be observed through two analyticalmethods. The first analytical method used to observe the presence ofstrain hardening on an extensional rheometer. During extensional ororiented flow on an extensional rheometer, strain hardening will occurwhen polymer entanglements do not allow the polymer to flow under LinearViscoelastic (LVE) conditions. As a result, these polymer entanglementshamper flow and create a deviation from the LVE conditions as observedas a hook formation. The strain hardening phenomenon becomes more severeas strain and strain rate increase due to faster and more severe polymerchain entanglement motion. Virgin polymers without long-chain branchingwill exhibit LVE flow characteristics. In comparison, long-chainbranched polymers will exhibit strain hardening and which causes adeviation from the LVE flow characteristics of the virgin polymerproviding the hook formation under the same test conditions.

The second analytical method used to observe the presence of long-chainbranching is evaluating melt strength data as tested per ISO 16790 whichis incorporated by reference herein in its entirety. An amount of meltstrength is known to be directly related to the presence of long-chainbranching when compared to similar virgin polymers lacking long-chainbranching. By way of example, Borealis DAPLOY™ WB140HMS Polypropylene(PP) (available from Borealis AG) is compared to other polymers havingsimilar molecular weight, polydispersity index, and other physicalcharacteristics. The DAPLOY™ WB140HMS PP has a melt strength whichexceeds about 36 cN while other similar PP resins lacking long-chainbranching have a melt strength of less than about 10 cN.

Melt flow index (MFI) is an indirect measure of the viscosity of apolymer when molten. The index is defined as the mass of polymer meltthat will flow through a capillary of a specific diameter and length bya pressure applied in 10 minutes, as described in ASTM D1238 Forexample, the Marlex® HHM 5502BN HDPE hexene copolymer (Chevron Phillips)has a melt flow index of 0.35 g/10 min per ASTM D1238. A larger meltindex value indicates a lower viscosity. Higher molecular weightpolymers will be more viscous and less will flow under the sameconditions so the melt index will be a smaller number.

In certain exemplary embodiments, the formulation may include two baseresins that are HDPE. One illustrative example of the formulationincludes a first base resin of FORMOLENE® HB5502F HDPE hexene copolymer(available from Formosa Plastics Corporation) and a second base resin ofEQUISTAR® ALATHON® H5520 HDPE copolymer (available from LyondellChemical Company). In embodiments with more than one HDPE copolymer,different HDPE copolymers can be used depending on the attributesdesired in the formulation. For example, a formulation may include bothelectron-beam modified EQUISTAR® ALATHON® H5520 and FORMOLENE® HB5502FHDPE. In such an embodiment, the EQUISTAR® ALATHON® H5520 provideshigher melt strength which increases foaming potential, and has lessflexural modulus or brittleness. The FORMOLENE® HB5502F HDPE provideswide unimodal polydispersity index of the molecular weight distributionand maximizes economic advantage.

In another example, a formulation includes about 50% electron-beammodified EQUISTAR® ALATHON® H5520 and about 50% FORMOLENE® HB5502F HDPE.The combination provides a material having drop resistance capabilityassociated with a non-modified HDPE resin and increased melt strength ofan electron-beam modified long-chain branched HDPE. Depending on thedesired characteristics, the percentage of the HDPE base resin betweenthe two HDPE base resins may be varied, e.g., 25%/75%, 30%/70%, 35%/65%,40%/60%, 45%/55%, 50%/50%, etc., by weight of the base resins. In anembodiment, a formulation includes three HDPE base resins. Again,depending on the desired characteristics, the percentage of three HDPEcopolymers can be varied, 33%/33%/33%, 30%/30%/40%, 25%/25%/50%, etc.,by weight of the base resins.

Polymeric material as disclosed herein includes at least one base resin.In illustrative embodiments, the at least one base resin can be HDPE.The amount of a base resin may be one of several different values orfall within one of several different ranges. It is within the scope ofthe present disclosure to select an amount of base resin to be one ofthe following values: about 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%,70%, 75%, 80%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%,96%, 97%, 98%, 99%, 99.5%, and 99.9% of the total formulation of thepolymeric layer by weight percentage. It is within the presentdisclosure for the amount of base resin in the formulation to fallwithin one of many different ranges. In a first set of ranges, the rangeof base resin is one of the following ranges: about 25% to 99.9%, 85% to99.9%, 90% to 99.9%, 95% to 99.9%, 98% to 99.9%, and 99% to 99.9% of thetotal formulation of the polymeric layer by weight percentage. In asecond set of ranges, the range of base resin is one of the followingranges: about 85% to 99%, 85% to 98%, 85% to 95%, and 85% to 90% of thetotal formulation of the polymeric layer by weight percentage. In athird set of ranges, the range of base resin is one of the followingranges: about 90% to 99% and 95% to 98% of the total formulation byweight percentage. Each of these values and ranges is embodied inExamples 1 to 13. In an embodiment, the base resin can be 100% virginbase resin. In an embodiment, the base resin can be a mixture of virginbase resin and regrind base resin. For example, the base resin can be100%, 90%, 80%, 75%, 70%, 60%, 50%, 40%, 30%, 25%, 20%, or 10% virginbase resin with the remainder being a regrind. For example, the baseresin can be 50% virgin HDPE and 50% regrind.

The term polymeric layer refers to a polymeric monolayer, a polymericcore layer in a multilayer material, or a non-core polymeric layer in amultilayer material.

The formulation used to produce the insulative cellular non-aromaticpolymeric material may further include one or more cell-forming agents.Cell-forming agents include nucleating agents and blowing agents. Anucleating agent is used to provide and control nucleation sites withina molten formulation to promote formation of cells, bubbles, or voids inthe molten formulation during extrusion. A blowing agent is used to growcells in the molten material at nucleation sites. Blowing agents may beused alone in the formulation or with nucleating agents.

Formulations used to produce insulative cellular non-aromatic polymericmaterials may include one or more cell-forming agents. The amount of anucleating agent may be one of several different values or fall withinone of several different ranges. It is within the scope of the presentdisclosure to select an amount of a nucleating agent to be one of thefollowing values: about 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%,11%, 12%, 13%, 14%, and 15%, of the total formulation of the polymericlayer by weight percentage. It is within the scope of the presentdisclosure for the amount of a physical nucleating agent in theformulation to fall within one of many different ranges. In a first setof ranges, the range of a physical nucleating agent is one of thefollowing ranges: about 0.1% to 15% (w/w), 0.25% to 15%, 0.5% to 15%,0.75% to 15%, 1% to 15%, 2% to 15%, 3% to 15%, 4% to 15%, and 5% to 15%of the total formulation of the polymeric layer by weight percentage. Ina second set of ranges, the range of a nucleating agent is one of thefollowing ranges: about 0.1% to 10%, 0.25% to 10%, 0.5% to 10%, 0.75% to10%, 1% to 10%, 2% to 10%, 3% to 10%, 4% to 10%, and about 5% to 10% ofthe total formulation of the polymeric layer by weight percentage. In athird set of ranges, the range of a nucleating agent is one of thefollowing ranges: about 0.1% to 5%, 0.25% to 5%, 0.5% to 5%, 0.75% to5%, 1% to 5%, 1.5% to 5%, 2% to 5%, 2.5% to 5%, 3% to 5%, 3.5% to 5%, 4%to 5%, and 4.5% to 5% of the total formulation of the polymeric layer byweight percentage.

Nucleating agent means a chemical or physical agent that provides sitesfor cells to form in a molten material. Nucleating agents may includechemical nucleating agents and physical nucleating agents. Thenucleating agent may be blended with the formulation that is introducedinto the hopper of the extruder. Alternatively, the nucleating agent maybe added to the molten resin mixture in the extruder.

Suitable physical nucleating agents have desirable particle size, aspectratio, and top-cut properties. Examples include, but are not limited to,talc, CaCO₃, mica, and mixtures of at least two of the foregoing. Onerepresentative example is Heritage Plastics HT6000 Linear Low DensityPolyethylene (LLDPE) Based Talc Concentrate.

Formulations used to produce insulative cellular non-aromatic polymericmaterials may include one or more cell-forming agents. The amount of aphysical nucleating agent may be one of several different values or fallwithin one of several different ranges. It is within the scope of thepresent disclosure to select an amount of physical nucleating agent,such as talc, to be one of the following values: about 0%, 1%, 2%, 3%,4%, 5%, 6%, and 7% of the total formulation of the polymeric layer byweight percentage. It is within the scope of the present disclosure forthe amount of a physical nucleating agent in the formulation to fallwithin one of many different ranges. In a first set of ranges, the rangeof a physical nucleating agent is one of the following ranges: about 0%to 7% (w/w), 0.1% to 7%, 0.25% to 7%, 0.5% to 7%, 0.75% to 7%, 1.0% to7%, 1.25% to 7%, 1.5% to 7%, 1.75% to 7%, 2.0% to 7%, 2.25% to 7%, 2.5%to 7%, 3% to 7%, 4% to 7%, 5% to 7%, and 6% to 7% of the totalformulation of the polymeric layer. In a second set of ranges, the rangeof a physical nucleating agent is one of the following ranges: about 0%to 6%, 0% to 5%, 0% to 4%, 0% to 3.0%, 0% to 2.5%, 0% to 2.25%, 0% to2.0%, 0% to 1.75%, 0% to 1.5%, 0% to 1.25%, 0% to 1.0%, 0% to 0.75%, and0% to 0.5% of the total formulation of the polymeric layer. In a thirdset of ranges, the range of a physical nucleating agent is one of thefollowing ranges: about 0.1% to 6%, 0.5% to 5%, 1% to 4%, and 2% to 3%of the total formulation of the polymeric layer. In an embodiment, theformulation lacks talc.

Suitable chemical nucleating agents decompose to create cells in themolten formulation when a chemical reaction temperature is reached.These small cells act as nucleation sites for larger cell growth from aphysical or other type of blowing agent. In one example, the chemicalnucleating agent is citric acid or a citric acid-based material. Onerepresentative example is HYDROCEROL™ CF-40E (available from ClariantCorporation), which contains citric acid and a crystal nucleating agent.

A blowing agent refers to a physical or a chemical material (orcombination of materials) that acts to expand nucleation sites. Blowingagents may include only chemical blowing agents, only physical blowingagents, combinations thereof, or several types of chemical and physicalblowing agents. The blowing agent acts to reduce density by formingcells in the molten formulation at the nucleation sites. The blowingagent may be added to the molten resin mixture in the extruder.

Chemical blowing agents are materials that degrade or react to produce agas. Chemical blowing agents may be endothermic or exothermic. Chemicalblowing agents typically degrade at a certain temperature to decomposeand release gas. One example of a chemical blowing agent is citric acidor citric-based material. One representative example is HYDROCEROL™CF-40E (available from Clariant Corporation), which contains citric acidand a crystal nucleating agent. Here, the citric acid decomposes at theappropriate temperature in the molten formulation and forms a gas whichmigrates toward the nucleation sites and grows cells in the moltenformulation. If sufficient chemical blowing agent is present, thechemical blowing agent may act as both the nucleating agent and theblowing agent. However, a chemical blowing agent does not always act asa nucleating agent.

In another example, chemical blowing agents may be selected from thegroup consisting of azodicarbonamide; azodiisobutyro-nitrile;benzenesulfonhydrazide; 4,4-oxybenzene sulfonylsemicarbazide; p-toluenesulfonyl semi-carbazide; barium azodicarboxylate;N,N′-dimethyl-N,N′-dinitrosoterephthalamide; trihydrazino triazine;methane; ethane; propane; n-butane; isobutane; n-pentane; isopentane;neopentane; methyl fluoride; perfluoromethane; ethyl fluoride;1,1-difluoroethane; 1,1,1-trifluoroethane; 1,1,1,2-tetrafluoro-ethane;pentafluoroethane; perfluoroethane; 2,2-difluoropropane;1,1,1-trifluoropropane; perfluoropropane; perfluorobutane;perfluorocyclobutane; methyl chloride; methylene chloride; ethylchloride; 1,1,1-trichloroethane; 1,1-dichloro-1-fluoroethane;1-chloro-1,1-difluoroethane; 1,1-dichloro-2,2,2-trifluoroethane;1-chloro-1,2,2,2-tetrafluoroethane; trichloromonofluoromethane;dichlorodifluoromethane; trichlorotrifluoroethane;dichlorotetrafluoroethane; chloroheptafluoropropane;dichlorohexafluoropropane; methanol; ethanol; n-propanol; isopropanol;sodium bicarbonate; sodium carbonate; ammonium bicarbonate; ammoniumcarbonate; ammonium nitrite;N,N′-dimethyl-N,N′-dinitrosoterephthalamide;N,N′-dinitrosopentamethylene tetramine; azodicarbonamide;azobisisobutylonitrile; azocyclohexylnitrile; azodiaminobenzene;bariumazodicarboxylate; benzene sulfonyl hydrazide; toluene sulfonylhydrazide; p,p′-oxybis(benzene sulfonyl hydrazide); diphenylsulfone-3,3′-disulfonyl hydrazide; calcium azide; 4,4′-diphenyldisulfonyl azide; p-toluene sulfonyl azide, and combinations thereof.

In one aspect of the present disclosure, where a chemical blowing agentis used, the chemical blowing agent may be introduced into the materialformulation that is added to the hopper.

Formulations used to produce insulative cellular non-aromatic polymericmaterials may include one or more chemical blowing agents. The amount ofa chemical blowing agent may be one of several different values or fallwithin one of several different ranges. It is within the scope of thepresent disclosure to select an amount of a chemical blowing agent to beone of the following values: about 0%, 0.1%, 0.5%, 0.75%, 1%, 1.5%, 2%,3%, 4%, and 5%, of the total formulation of the polymeric layer byweight percentage. It is within the scope of the present disclosure forthe amount of a physical nucleating agent in the formulation to fallwithin one of many different ranges. In a first set of ranges, the rangeof a physical nucleating agent is one of the following ranges: about0.1% to 5% (w/w), 0.25% to 5%, 0.5% to 5%, 0.75% to 5%, 1% to 5%, 1.5%to 5%, and 2% to 5% of the total formulation of the polymeric layer byweight percentage. In a second set of ranges, the range of a nucleatingagent is one of the following ranges: about 0.1% to 2%, 0.25% to 2%,0.5% to 2%, 0.75% to 2%, 1% to 2%, and 1.5% to 2% of the totalformulation by weight percentage. In a third set of ranges, the range ofa nucleating agent is one of the following ranges: about 0.1% to 1%,0.25% to 1%, 0.5% to 1%, and 0.75% to 1%, of the total formulation ofthe polymeric layer by weight percentage.

One example of a physical blowing agent is nitrogen (N₂). The N₂ ispumped into the molten formulation via a port in the extruder as asupercritical fluid. The molten material with the N₂ in suspension thenexits the extruder via a die where a pressure drop occurs. As thepressure drop happens, N₂ moves out of suspension toward the nucleationsites where cells grow. Excess gas blows off after extrusion with theremaining gas trapped in the cells formed in the extrudate. Othersuitable examples of physical blowing agents include, but are notlimited to, carbon dioxide (CO₂), helium, argon, air, pentane, butane,or other alkane mixtures of the foregoing and the like. In anillustrative example, a physical blowing agent may be introduced at arate of about 0.02 pounds per hour to about 1.3 pounds per hour. Inanother illustrative example, the physical blowing agent may beintroduced at a rate of about 0.03 pounds per hour to about 1.25 poundsper hour. In another illustrative example, the physical blowing agentmay be introduced at a rate of about 0.03 to about 0.15 pounds per hour.In still yet another illustrative example, the physical blowing agentmay be introduced at a rate of about 0.05 pounds per hours to about 0.15pounds per hour.

In one aspect of the present disclosure, at least one slip agent may beincorporated into the formulation to aid in increasing production rates.Slip agent (also known as a process aid) is a term used to describe ageneral class of materials that is added to a formulation to providesurface lubrication to the polymer during and after conversion. Slipagents may also reduce or eliminate die drool. Representative examplesof slip agents include amides of fats or fatty acids, such as, but notlimited to, erucamide and oleamide. In one exemplary aspect, amides fromoleyl (single unsaturated C-18) through erucyl (C-22 single unsaturated)may be used. Other representative examples of a slip agent include lowmolecular weight amides and fluoroelastomers. Combinations of two ormore slip agents can be used. Slip agents may be provided in a masterbatch pellet form and blended with the resin formulation. One example ofa suitable slip agent is Ampacet 102823 Process Aid PE MB LLDPE.

Formulations used to produce insulative cellular non-aromatic polymericmaterials may include one or more slip agents. The amount of a slipagent may be one of several different values or fall within one ofseveral different ranges. It is within the scope of the presentdisclosure to select an amount of a slip agent to be one of thefollowing values: about 0%, 0.1%, 0.25%, 0.5%, 0.75%, 1%, 1.25%, 1.5%,1.75%, 2%, 2.25%, 2.5%, 2.75% and 3% of the total formulation of thepolymeric layer by weight percentage. It is within the scope of thepresent disclosure for the amount of a slip agent in the formulation tofall within one of many different ranges. In a first set of ranges, therange of a slip agent is one of the following ranges: about 0% to 3%(w/w), 0.1% to 3%, 0.25% to 3%, 0.5% to 3%, 0.75% to 3%, 1% to 3%, 1.25%to 3%, 1.5% to 3%, 1.75% to 3%, 2% to 3%, 2.25% to 3%, and 2.5% to 3% ofthe total formulation of the polymeric layer by weight percentage. In asecond set of ranges, the range of a slip agent is one of the followingranges: about 0% to 2.5%, 0% to 2.25%, 0% to 2%, 0% to 1.75%, 0% to1.5%, 0% to 1.25%, 0% to 1%, 0% to 0.75%, and 0% to 0.5% of the totalformulation of the polymeric layer by weight percentage. In a third setof ranges, the range of a slip agent is one of the following ranges:about 0.1% to 2.5%, 0.25% to 2.25%, 0.5% to 2%, 0.75%, to 1.75%, and 1%to 1.5% of the total formulation by weight percentage. In an embodiment,the formulation lacks a slip agent.

In another aspect of the present disclosure, an impact modifier may beincorporated into a formulation to minimize fracturing of the insulativecellular non-aromatic polymeric material when subjected to an impactsuch as a drop test. One representative example of a suitable impactmodifier is DOW® AFFINITY™ PL 1880G polyolefin plastomer.

Formulations used to produce insulative cellular non-aromatic polymericmaterials may include one or more colorants. The amount of a colorantmay be one of several different values or fall within one of severaldifferent ranges. It is within the scope of the present disclosure toselect an amount of a colorant to be one of the following values: about0%, 0.1%, 0.25%, 0.5%, 0.75%, 1%, 2%, 3%, and 4% of the totalformulation of the polymeric layer by weight percentage. It is withinthe scope of the present disclosure for the amount of a colorant in theformulation to fall within one of many different ranges. In a first setof ranges, the range of a colorant is one of the following ranges: about0% to 4% (w/w), 0.1% to 4%, 0.25% to 4%, 0.5% to 4%, 0.75% to 4%, 1% to4%, 1.25% to 4%, 1.5% to 4%, 1.75% to 4%, 2% to 4%, 2.25% to 4%, 2.5% to4%, and 3% to 4% of the total formulation of the polymeric layer byweight percentage. In a second set of ranges, the range of a colorant isone of the following ranges: about 0% to 3%, 0% to 2.5%, 0% to 2.25%, 0%to 2%, 0% to 1.75%, 0% to 1.5%, 0% to 1.25%, 0% to 1%, 0% to 0.75%, and0% to 0.5% of the total formulation of the polymeric layer by weightpercentage. In a third set of ranges, the range of a colorant is one ofthe following ranges: about 0.1% to 3.5%, 0.5% to 3%, 0.75% to 2.5%, and1% to 2% of the total formulation by weight percentage. In anembodiment, the formulation lacks a colorant.

A material-formulation process in accordance with the present disclosureuses a polyethylene-based formulation to produce a strip of insulativecellular non-aromatic polymeric material. Raw material according to thepolyethylene-based material is gravity fed into the barrel of anextruder where it is heated to produce a molten material. A cell-formingagent is then introduced into the molten material prior to extrusion. Asthe molten materials exit the extruder, cells nucleate in the moltenmaterial, and the molten material expands and cools to form a sheet ofinsulative cellular non-aromatic polymeric material.

An insulative cellular non-aromatic polymeric material produced inaccordance with the present disclosure can be formed to produce aninsulative cup or an insulative container. In another illustrativeexample, the insulative cellular non-aromatic polymeric materialproduces a monolayer tube or monolayer parison that is blow molded toform an insulative container (e.g., bottle). In an embodiment, amonolayer foamed bottle further includes an extruded second layer (i.e.,skin layer). In illustrative embodiments, a second layer can be linearlow density polyethylene (LLDPE), low density polyethylene (LDPE),medium density polyethylene (MDPE), high density polyethylene (HDPE),polypropylene homopolymer, polypropylene impact copolymer, polypropylenerandom polymer, polystyrene, polyethylene terephthalate (PET), orpolyvinyl chloride (PVC).

In an example, a multi-layer container includes a core layer and atleast one non-core layer. In an illustrative example, a core layer issandwiched between an inner polymeric layer and an outer polymericlayer. In an example, each layer (core and non-core layers) of themulti-layer container includes at least one HDPE base resin. In anembodiment, a non-core layer can include fiber. A suitable fiber can bea synthetic fiber that reinforces polyolefin formulations to provide,e.g., higher stiffness to the material and better feeding and handlingduring extrusion or blow molding process. A suitable fiber for apolymeric layer includes a synthetic, mineral based fiber, such asHyperform® HPR-803i (Milliken & Co., Spartanburg, S.C.). In anembodiment, one or more non-core polymeric layers includes fiber. In anillustrative embodiment, a multi-layer container has fiber in an outerpolymeric layer but an inner polymeric layer does not include fiber. Inan illustrative example, a multi-layer container is a bottle having a) acore layer comprising HDPE, a chemical blowing agent, and talc; b) anouter polymeric layer comprising HDPE, a colorant, and fiber; and c) aninner polymeric layer comprising HDPE and fiber. In an embodiment, themulti-layer bottle has a density of about 0.4 g/cm³ to about 0.5 g/cm³.

Non-core layers used to produce insulative cellular non-aromaticpolymeric materials may include fiber. The amount of fiber may be one ofseveral different values or fall within one of several different ranges.It is within the scope of the present disclosure to select an amount offiber to be one of the following values: about 5%, 10%, 15%, 20%, and25% of the layer by weight percentage. It is within the scope of thepresent disclosure for the amount of fiber in the layer to fall withinone of many different ranges. In a first set of ranges, the range offiber is one of the following ranges: about 0% to 25% (w/w), 5% to 25%,10% to 25%, 15% to 25%, and 20% to 25 of the total layer by weightpercentage. In a second set of ranges, the range of fiber is one of thefollowing ranges: about 0% to 25%, 0% to 20%, 0% to 15%, 0% to 10%, and0% to 5% of the total layer by weight percentage. In a third set ofranges, the range of a colorant is one of the following ranges: about 5%to 20%, 5% to 15%, 5% to 10%, 10% to 20%, and 10% to 15% of the totallayer by weight percentage. In an embodiment, non-core layers lackfiber.

In an embodiment, the insulative cellular non-aromatic polymericmaterial is located between and coupled to an inner polymeric layer andan outer polymeric layer to produce a multi-layer tube. For example, themulti-layer tube can be a bottle. The density of the tube may be one ofseveral different values or fall within one several different ranges. Itis within the scope of the present disclosure for the density of thetube to fall within one of many different ranges. In a first set ofranges, the density is one of the following ranges: about 0.5 g/cm³ to0.92 g/cm³, 0.6 g/cm³ to 0.92 g/cm³, 0.65 g/cm³ to 0.92 g/cm³, 0.7 g/cm³to 0.92 g/cm³, 0.75 g/cm³ to 0.92 g/cm³, 0.8 g/cm³ to 0.92 g/cm³, 0.85g/cm³ to 0.92 g/cm³, and 0.9 g/cm³ to 0.92 g/cm³. In a first set ofranges, the density is one of the following ranges: about 0.5 g/cm³ to0.9 g/cm³, 0.6 g/cm³ to 0.9 g/cm³, 0.65 g/cm³ to 0.9 g/cm³, 0.7 g/cm³ to0.9 g/cm³, 0.75 g/cm³ to 0.9 g/cm³, 0.8 g/cm³ to 0.9 g/cm³, and 0.85g/cm³ to 0.9 g/cm³. In a third set of ranges, the density is one of thefollowing ranges: about 0.6 g/cm³ to 0.85 g/cm³, 0.65 g/cm³ to 0.8g/cm³, and 0.7 g/cm³ to 0.75 g/cm³,

In an embodiment, the insulative cellular non-aromatic polymericmaterial is located between and coupled to an inner polymeric layer andan outer polymeric layer to produce a multi-layer parison. The densityof the multi-layer parison may be one of several different values orfall within one several different ranges. It is within the scope of thepresent disclosure for the density of the multi-layer parison to fallwithin one of many different ranges. In a first set of ranges, thedensity is one of the following ranges: about 0.4 g/cm³ to 0.8 g/cm³,0.45 g/cm³ to 0.8 g/cm³, 0.5 g/cm³ to 0.8 g/cm³, 0.55 g/cm³ to 0.8g/cm³, 0.6 g/cm³ to 0.8 g/cm³, 0.65 g/cm³ to 0.8 g/cm³, 0.7 g/cm³ to 0.8g/cm³, and 0.75 g/cm³ to 0.8 g/cm³. In a second set of ranges, thedensity of a multi-layer parison is one of the following ranges: about0.4 g/cm³ to 0.75 g/cm³, 0.4 g/cm³ to 0.7 g/cm³, 0.4 g/cm³ to 0.65g/cm³, 0.4 g/cm³ to 0.6 g/cm³, 0.4 g/cm³ to 0.55 g/cm³, 0.4 g/cm³ to 0.5g/cm³, and 0.4 g/cm³ to 0.45 g/cm³. In a third set of ranges, thedensity of a multi-layer parison is one of the following ranges: about0.45 g/cm³ to 0.7 g/cm³, 0.5 g/cm³ to 0.65 g/cm³, and 0.55 g/cm³ to 0.6g/cm³. Density was determined according to the density test procedureoutlined in Example 14.

In an embodiment, a throughput system includes a multi-parison drop. Forexample, an extrusion line starts as a single line and then splits into2, 3, 4, 5, or more lines for multiple parison drops. In an embodiment,the RPMs for the extrusion stream start at a particular level (e.g., 48RPM) and splits evenly into 2 (e.g., 24 RPM each), 3 (e.g., 16 RPMeach), 4 (12 RPM each), or more multi-parison drops splitting the RPMs.A more efficient output can be achieved by splitting the extrusionstream into multiple parison drop streams. Thereby, an embodimentincludes a system comprising an extrusion stream that splits intomultiple parison streams. In an embodiment, the system provides multiplefoamed parison drops. Such a system that splits the extrusion line intomultiple parison drops can produce foamed bottle. In an embodiment, thefoamed bottles have densities as described herein.

Containers (e.g., bottles) can be subjected to a drop test, which is atest to determine a container's ability to withstand free-fall impactforces. Containers that do not pass the drop test are not suitable forcommercial applications. In an illustrative embodiment, the insulativecellular non-aromatic polymeric material is coupled and located betweentwo polymeric layers to form a multi-layer parison. The multi-layerparison is then formed, for example, via blow molding into a container.The container is then filled with water and closed off with, forexample, a lid. The sample container is then held at about 73 degreesFahrenheit (22.8 degrees Celsius) and about 50% relative humidity. Thefilled, capped containers are then subjected to the following drop testprocedure: (a) the filled, capped container is located at about fivefeet above a hard surface such as concrete or tile; (b) the filled,capped container is then oriented such that a bottom of the filled,capped container is arranged to lie in substantially parallel relationto the hard surface; (c) each of ten capped, filled containers aredropped; (d) upon impact, each filled, capped container is examined forany break or shattering of the wall that causes water to leak out of thebottle; and (d) the total number of bottles showing any sign of leakageafter the drop test are counted as failures.

A method of producing a container or parison as described hereinincludes extruding or blow-molding any of the formulations describedherein.

In an illustrative embodiment, a formulation for producing an insulativecellular non-aromatic polymeric material includes 98% HDPE, 0.5%chemical blowing agent (CBA), and 1.5% nucleating agent (e.g., talc).The formulation can be used to produce a material that is a) a monolayerforming a container or parison or b) the core layer in a multi-layercontainer or parison. In an illustrative multi-layer embodiment, a corelayer of 98% HDPE, 0.5% CBA, and 1.5% nucleating agent can be sandwichedbetween at least one inner polymeric layer and at least one outerpolymeric layer. An illustrative outer polymeric layer includes i) 80%HDPE, ii) 5% colorant, and iii) 15% fiber. An illustrative innerpolymeric layer includes 85% HDPE and 15% fiber.

In an illustrative embodiment, a formulation for producing an insulativecellular non-aromatic polymeric material includes 98.75% HDPE, 0.75%chemical blowing agent (CBA), and 0.2% nucleating agent (e.g., talc).

In an illustrative embodiment, a formulation for producing an insulativecellular non-aromatic polymeric material includes 98% HDPE and 2.0%chemical blowing agent (CBA).

In an illustrative embodiment, a formulation for producing an insulativecellular non-aromatic polymeric material includes 96.5% HDPE, 0.5%chemical blowing agent (CBA), 2% slip agent, and 1% colorant.

In an illustrative embodiment, a formulation for producing an insulativecellular non-aromatic polymeric material includes 95% HDPE, 1.5%chemical blowing agent (CBA), 2% slip agent, 0.5% nucleating agent(e.g., talc) and 1% colorant, wherein the 95% is a 50%/50% blend of twoseparate HDPE resins. Thus, each HDPE resin is 47.5% of the totalformulation of the polymeric layer by weight percentage.

In an illustrative embodiment, a formulation for producing an insulativecellular non-aromatic polymeric material includes 82.54% HDPE, 0.62%chemical blowing agent (CBA), 2.49% slip agent, 11.16% nucleating agent(e.g., talc) and 3.19% colorant.

The following numbered paragraphs define particular embodiments of theinsulative cellular non-aromatic polymeric material formulation of theinvention:

-   -   1) 80-99.9 wt % of at least one HDPE polymeric resin;    -   0.1-12 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally, the balance of the formulation comprising one or        more additives selected from slip agents, colorants and impact        modifiers.    -   2) 80-99.9 wt % of at least one HDPE polymeric resin;    -   0.1-12 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.5-3 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   3) 84-99.9 wt % of at least one HDPE polymeric resin;    -   0.1-3 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   4) 84-99.9 wt % of at least one HDPE polymeric resin;    -   0.1-3 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.5-3 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   5) 85-99.9 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   6) 85-99.9 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.5-3 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   7) 85-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   8) 85-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.5-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   9) 87-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   10) 87-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   11) 90-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   12) 90-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.5 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   13) 90-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.2 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   14) 90-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.2 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   15) 92-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.2 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   16) 92-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.2 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   17) 95-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.0 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   18) 95-99.7 wt % of at least one HDPE polymeric resin;    -   0.1-2.0 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   19) 95-99.5 wt % of at least one HDPE polymeric resin;    -   0.1-2.0 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents; and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   20) 95-99.5 wt % of at least one HDPE polymeric resin;    -   0.1-2.0 wt % of at least one nucleating agent selected from        physical nucleating agents and chemical nucleating agents;    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.

In any of the numbered paragraphs (1)-(20) above, the one or more HDPEpolymeric resin may be selected from HDPE homopolymer or HDPE copolymer.Suitably, the one or more HDPE polymeric resin is selected from DOW®DOWLEX™ IP 41 HDPE (available from The Dow Chemical Company) that hasbeen electron-beam modified to provide long-chain branching and a meltindex of about 0.25 g/10 min, EQUISTAR® ALATHON® H5520 HDPE copolymer(available from Lyondell Chemical Company) that has been electron-beammodified to have long-chain branching and a melt index of about 0.25g/10 min, FORMOLENE® HB5502F HDPE hexene copolymer (available fromFormosa Plastics Corporation), and Marlex® HHM 5502BN HDPE hexenecopolymer. In one embodiment, the one or more HDPE polymeric resin isDOW® DOWLEX™ IP 41 HDPE. In another embodiment, the one or more HDPEpolymeric resin is DOW® DOWLEX™ IP 41 HDPE and FORMOLENE® HB5502F HDPEhexene copolymer. In another embodiment, the one or more HDPE polymericresin is FORMOLENE® HB5502F HDPE hexene copolymer and EQUISTAR® ALATHON®H5520 HDPE copolymer. In one embodiment, the one or more HDPE polymericresin is DOW® DOWLEX™ IP 41 HDPE and Marlex® HHM 5502BN HDPE hexenecopolymer.

In any of the numbered paragraphs (1)-(20) above, the at least onenucleating agent may be a physical nucleating agent selected from talc,CaCO3 and/or mica, and/or a chemical nucleating agent selected fromcitric acid or a citric acid-based material (e.g. HYDROCEROL™ CF-40E,available from Clariant Corporation). In one embodiment, the at leastone nucleating agent is a mixture of talc and HYDROCEROL™ CF-40E. Inanother embodiment, the at least one nucleating agent is talc. Inanother embodiment, the at least one nucleating agent is HYDROCEROL™CF-40E.

In any of the numbered paragraphs (1)-(20) above, the at least one slipagent may be selected from amides, fluoroelastomers, amides of fats orfatty acids, such as erucamide and oleamide, and amides from oleyl(single unsaturated C-18) through erucyl (C-22 single unsaturated). Inone embodiment, the at least one slip agent is Ampacet 102823 ProcessAid PE MB LLDPE.

In any of the numbered paragraphs (1)-(20) above, the colorant(s) may beselected from any suitable colorant. In one embodiment, the colorant isCOLORTECH® 11933-19 Titanium Oxide Colorant.

In any of the numbered paragraphs (1)-(20) above, the impact modifier(s)may be selected from any suitable impact modifier. In one embodiment,the impact modifier is DOW® AFFINITY™ PL 1880G polyolefin plastomer.

The following numbered paragraphs define particular embodiments of theinsulative cellular non-aromatic polymeric material formulation of theinvention:

-   -   21) 80-99.9 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, FORMOLENE® HB5502F HDPE hexene copolymer, and Marlex®        HHM 5502BN HDPE hexene copolymer;    -   0.1-7 wt % of at least one nucleating agent selected from talc,        CaCO₃, mica, and/or a chemical nucleating agent selected from        citric acid or a citric acid-based material (e.g. HYDROCEROL™        CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   22) 80-99.9 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, FORMOLENE® HB5502F HDPE hexene copolymer, and Marlex®        HHM 5502BN HDPE hexene copolymer;    -   0.1-7 wt % of at least one nucleating agent selected from talc,        CaCO₃, mica, and/or a chemical nucleating agent selected from        citric acid or a citric acid-based material (e.g. HYDROCEROL™        CF-40E);    -   0.5-3 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   23) 84-99.9 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, FORMOLENE® HB5502F HDPE hexene copolymer, and Marlex®        HHM 5502BN HDPE hexene copolymer;    -   0.1-3 wt % of at least one nucleating agent selected from talc,        CaCO₃, mica, and/or a chemical nucleating agent selected from        citric acid or a citric acid-based material (e.g. HYDROCEROL™        CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   24) 84-99.9 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-3 wt % of at least one nucleating agent selected from talc,        CaCO₃, mica, and/or a chemical nucleating agent selected from        citric acid or a citric acid-based material (e.g. HYDROCEROL™        CF-40E);    -   0.5-3 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   25) 85-99.9 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   26) 85-99.9 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.5-3 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   27) 85-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   28) 85-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.5-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   29) 87-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   30) 87-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   31) 90-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   32) 90-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.5 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   33) 90-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.2 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   34) 90-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.2 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   35) 92-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.2 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   36) 92-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.2 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   37) 95-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.0 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   38) 95-99.7 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.0 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.    -   39) 95-99.5 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.0 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E); and    -   optionally the balance of the formulation comprising one or more        additives selected from slip agents, colorants and impact        modifiers.    -   40) 95-99.5 wt % of at least one HDPE polymeric resin selected        from DOW® DOWLEX™ IP 41 HDPE, EQUISTAR® ALATHON® H5520 HDPE        copolymer, and FORMOLENE® HB5502F HDPE hexene copolymer, and        Marlex® HHM 5502BN HDPE hexene copolymer;    -   0.1-2.0 wt % of at least one nucleating agent selected from        talc, CaCO₃, mica, and/or a chemical nucleating agent selected        from citric acid or a citric acid-based material (e.g.        HYDROCEROL™ CF-40E);    -   0.8-2.5 wt % of at least one slip agent; and    -   optionally the balance of the formulation comprising one or more        additives selected from colorants and impact modifiers.

In any of the numbered paragraphs (20)-(40) above, the at least one slipagent may be selected from amides, fluoroelastomers, amides of fats orfatty acids, such as erucamide and oleamide, and amides from oleyl(single unsaturated C-18) through erucyl (C-22 single unsaturated). Inone embodiment, the at least one slip agent is Ampacet 102823 ProcessAid PE MB LLDPE.

In any of the numbered paragraphs (20)-(40) above, the colorant(s) maybe selected from any suitable colorant. In one embodiment, the colorantis COLORTECH® 11933-19 Titanium Oxide Colorant.

In any of the numbered paragraphs (20)-(40) above, the impactmodifier(s) may be selected from any suitable impact modifier. In oneembodiment, the impact modifier is DOW® AFFINITY™ PL 1880G polyolefinplastomer.

One or more additional components and additives optionally may beincorporated, such as, but not limited to, colorants (such as, but notlimited to, titanium dioxide), and compound regrind.

Example 1 Formulation and Extrusion

DOW® DOWLEX™ IP 41 HDPE was used as the polyethylene base resin. Thepolyethylene base resin was blended with HYDROCEROL® CF 40E as anucleating agent and N2 as a blowing agent. Ampacet 102823 Process AidPE MB LLDPE was added as a slip agent and COLORTECH® 11933-19 was addedas a colorant. The percentages were about:

96.5% DOW ® DOWLEX ™ IP 41 HDPE 0.5% HYDROCEROL ® CF 40E 2.0% Ampacet102823 Process Aid PE MB LLDPE 1.0% COLORTECH ® 11933-19 Titanium OxideColorant

The HDPE, nucleating agents, slip agent, and colorant were added to anextruder hopper and blended to provide a formulation. The formulationwas then heated in the extruder to form a molten material. The blowingagent was then added to the molten material at a rate of about:

0.092 lbs/hr N2

The N2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison. Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which was then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers to form a multi-layer parison having adensity of about 0.480 grams per cubic centimeter. The multi-layerparison was then blow molded to establish an insulative container havinga density of about 0.695 grams per cubic centimeter.

Example 2 Formulation and Extrusion

DOW® DOWLEX™ IP 41 HDPE was used as the polyethylene base resin. Thepolyethylene base resin was blended with Heritage Plastics HT6000 LLDPEtalc as a nucleating agent, HYDROCEROL® CF 40E as another nucleatingagent, and N2 as a blowing agent. Ampacet 102823 Process Aid PE MB LLDPEwas added as a slip agent and COLORTECH® 11933-19 was added as acolorant. The percentages were about:

87.4% DOW ® DOWLEX ™ IP 41 HDPE 5.33% Heritage Plastics HT6000 LLDPEBased Talc Concentrate 3.88% COLORTECH ® 11933-19 Titanium OxideColorant 1.45% HYDROCEROL ® CF 40E 1.94% Ampacet 102823 Process Aid PEMB LLDPE

The HDPE, nucleating agents, slip agent, and colorant were added to anextruder hopper and blended to provide a formulation. The formulationwas then heated in the extruder to form a molten material. The blowingagent was then added to the molten material at a rate of about:

0.092 lbs/hr N2

The N2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison. Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which is then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers and blow molded to establish andinsulative container. The insulative container has a density of about0.770 grams per cubic centimeter.

Example 3 Formulation and Extrusion

DOW® DOWLEX™ IP 41 HDPE was used as the polyethylene base resin. Thepolyethylene base resin was blended with Heritage Plastics HT6000 LLDPEtalc as a nucleating agent, HYDROCEROL® CF 40E as another nucleatingagent, and N₂ as a blowing agent. Ampacet 102823 Process Aid PE MB LLDPEwas added as a slip agent and COLORTECH® 11933-19 was added as acolorant. The percentages were about:

87.4% DOW ® DOWLEX ™ IP 41 HDPE  6.3% Heritage Plastics HT6000 LLDPEBased Talc Concentrate 3.19% COLORTECH ® 11933-19 Titanium OxideColorant 0.62% HYDROCEROL ® CF 40E 2.49% Ampacet 102823 Process Aid PEMB LLDPE

The HDPE, nucleating agents, slip agent, and colorant were added to anextruder hopper and blended to provide a formulation. The formulationwas then heated in the extruder to form a molten material. The blowingagent was then added to the molten material at a rate of about:

0.092 lbs/hr N2

The N2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which is then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers and blow molded to establish andinsulative container. The insulative container has a density of about0.750 grams per cubic centimeter.

Example 4 Formulation and Extrusion

DOW® DOWLEX™ IP 41 HDPE was used as the polyethylene base resin. Thepolyethylene base resin was blended with HYDROCEROL® CF 40E as anucleating agent and CO2 as a blowing agent. Ampacet 102823 Process AidPE MB LLDPE was added as a slip agent and COLORTECH® 11933-19 was addedas a colorant. The percentages were about:

98.25%  DOW ® DOWLEX ™ IP 41 HDPE 0.25%  HYDROCEROL ® CF 40E 0.5%COLORTECH ® 11933-19 Titanium Oxide Colorant 1.0% Ampacet 102823 ProcessAid PE MB LLDPE

The HDPE, nucleating agent, slip agent, and colorant were added to anextruder hopper and blended to provide a formulation. The formulationwas then heated in the extruder to form a molten material. The blowingagent was then added to the molten material at a rate of about:

0.09 lbs/hr CO2

The CO2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which is then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers and blow molded to establish andinsulative container. The insulative container has a density of about0.794 grams per cubic centimeter.

Example 5 Formulation and Extrusion

FORMOSA PLASTICS® FORMOLENE™ HB5502F HDPE hexene copolymer was used asthe polyethylene base resin. The polyethylene base resin was blendedwith HYDROCEROL® CF 40E as a nucleating agent, Heritage Plastics HT6000LLDPE talc as another nucleating agent, and N2 as a blowing agent. Thepercentages were about:

98.75% FORMOLENE(T) HB5502F HDPE hexene copolymer  0.2% HeritagePlastics HT6000 LLDPE Based Talc Concentrate  0.75% HYDROCEROL ® CF 40E

The HDPE and nucleating agents were added to an extruder hopper andblended to provide a formulation. The formulation was then heated in theextruder to form a molten material. The blowing agent was then added tothe molten material at a rate of about:

0.125 lbs/hr N2

The N2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison. Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which is then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers to form a multi-layer parison having adensity of about 0.399 grams per cubic centimeter. The multi-layerparison was then blow molded to establish an insulative container havinga density of about 0.610 grams per cubic centimeter.

Example 6 Formulations and Test Results

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer was used asthe polyethylene base resin. To that polyethylene base resin, one ormore nucleating agents such as HYDROCEROL® CF 40E, Heritage PlasticsHT6000 LLDPE talc, or Heritage Plastics HT4HP were added. In addition,N2 or CO2 were added as a blowing agent. Furthermore, in some examples,Ampacet 102823 Process Aid PE MB LLDPE was added as a slip agent andCOLORTECH® 11933-19 was added as a colorant. The various formulationsand resulting multi-layer parison and insulative container densities areshown below in Table 1.

TABLE 1 Comparison of different insulative cellular non-aromaticpolymeric material formulations to create various multi-layer parisonand insulative container densities Bottle Parison Base Additive AdditiveAdditive Additive Gas Density Density Trial Resin #1 #2 #3 #4 [lbs/hr][g/cm³] [g/cm³] 6.1 96.5% 0.5% 2% 1% 0.09 CO2 0.797 0.481 Formosa CF-40EAmpacet Colortech 6.2 95% 1.5% 2% 1% 0.5% 0.08 CO2 0.806 0.455 FormosaCF-40E Ampacet Colortech HT4HP 6.3 95% 1.5% 2% 1% 0.5% 0.11 CO2 0.7530.451 Formosa CF-40E Ampacet Colortech HT4HP 6.4 95% 1.5% 2% 1% 0.5%0.09 N2 0.690 0.455 Formosa CF-40E Ampacet Colortech HT4HP 6.5 95% 1.5%2% 1% 0.5% 0.09 N2 0.693 0.447 Formosa CF-40E Ampacet Colortech HT4HP6.6 95% 1.5% 2% 1% 0.5% 0.09 N2 0.718 0.467 Formosa CF-40E AmpacetColortech HT4HP 6.7 96% 0.5% 2% 1% 0.5% 0.09 N2 0.785 0.503 FormosaCF-40E Ampacet Colortech HT4HP 6.8 96% 0.5% 2% 1% 0.5% 0.09 N2 0.7880.516 Formosa CF-40E Ampacet Colortech HT4HP 6.9 96% 0.5% 2% 1% 0.5%0.09 N2 0.736 0.495 Formosa CF-40E Ampacet Colortech HT4HP 6.10 96% 0.5%2% 1% 0.5% 0.09 N2 0.752 0.496 Formosa CF-40E Ampacet Colortech HT4HP6.11 96% 0.5% 2% 1% 0.5% 0.09 N2 0.749 0.473 Formosa CF-40E AmpacetColortech HT4HP 6.12 96.5% 0.5% 2% 1% 0.09 N₂ 0.779 0.498 Formosa CF-40EAmpacet Colortech 6.13 99.9% 0.1% 0.03 N₂ 0.918 0.785 Formosa CF-40E6.14 99.4% 0.1% 0.5% 0.1 N₂ 0.730 0.502 Formosa CF-40E HT6000 6.15 97.4%0.1% 2.5% 0.125 0.632 0.434 Formosa CF-40E HT6000 N₂ 6.16 99.25% 0.75%0.1 N₂ 0.723 0.688 Formosa CF-40E 6.17 98.75% 0.75% 0.5% 0.125 0.6060.568 Formosa CF-40E HT6000 N₂ 6.18 96.75% 0.75% 2.5% 0.03 N₂ 0.8920.470 Formosa CF-40E HT6000 6.19 98% 2.0% 0.125 0.481 0.416 FormosaCF-40E N₂ 6.20 97.5% 2% CF- 0.5% 0.03 N₂ 0.846 0.478 Formosa 40E HT60006.21 95.5% 2% CF- 2.5% 0.1 N₂ 0.597 0.411 Formosa 40E HT6000 6.22 98.75%0.75% 0.4% 0.125 0.573 0.414 Formosa CF-40E HT6000 N₂

Example 7 Formulations and Test Results

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer was used asthe polyethylene base resin. To that polyethylene base resin,HYDROCEROL® CF 40E and Heritage Plastics HT6000 LLDPE talc as nucleatingagents were added. In addition, N2 was added as a blowing agent. Thepercentages were about:

98.75% FORMOLENE(T) HB5502F HDPE hexene copolymer  0.75% HYDROCEROL ® CF40E  0.3% Heritage Plastics HT6000 LLDPE Based Talc Concentrate

The HDPE and nucleating agents were added to an extruder hopper andblended to provide a formulation. The formulation was then heated in theextruder to form a molten material. A blowing agent was then added tothe molten material at a rate of about:

0.12 lbs/hr N2

The N2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which is then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers to form a multi-layer parison having adensity of about 0.407 grams per cubic centimeter. The multi-layerparison was then blow molded to establish an insulative container havinga density of about 0.577 grams per cubic centimeter.

Example 8 Formulation and Extrusion

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer and EQUISTAR®ALATHON® H5520 HDPE copolymer were used as polyethylene base resins. Thepolyethylene base resins were blended with HYDROCEROL® CF 40E as anucleating agent and Heritage Plastics HT6000 LLDPE talc as anothernucleating agent, and N2 as a blowing agent. Ampacet 102823 Process AidPE MB LLDPE was added as a slip agent and COLORTECH® 11933-19 was addedas a colorant. The percentages were about:

47.5%  FORMOLENE ® HB5502F HDPE hexene copolymer 47.5%  EQUISTAR ®ALATHON ® H5520 HDPE copolymer 0.5% Heritage Plastics HT4HP Talc 1.5%HYDROCEROL ® CF 40E 2.0% Ampacet 102823 Process Aid PE MB LLDPE 1.0%COLORTECH ® 11933-19 Titanium Oxide Colorant

The HDPE, nucleating agents, slip agents, and colorants were added to anextruder hopper and blended to provide a formulation. The formulationwas then heated in the extruder to form a molten material. The blowingagent was then added to the molten material at a rate of about:

0.12 lbs/hr N2

The N2 was injected into the molten material to expand the moltenmaterial and reduce density of the insulative cellular non-aromaticpolymeric material. The resulting mixture was then extruded through adie head to establish a parison. Inner and outer polymeric layers werealso extruded to locate the insulative cellular non-aromatic polymericmaterial therebetween to form a multi-layer parison which is then blowmolded to form the insulative container.

Test Results

The insulative cellular non-aromatic polymeric material was mated toinner and outer polymeric layers to form a multi-layer parison having adensity of about 0.396 grams per cubic centimeter. The multi-layerparison was then blow molded to establish an insulative container havinga density of about 0.519 grams per cubic centimeter.

Example 9 Formulations and Test Results

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer and EQUISTAR®ALATHON® H5520 HDPE copolymer were used as polyethylene base resins. Thepolyethylene base resins were used in various percentages from about23.875% to about 74.925% of the formulation. The polyethylene baseresins were blended with HYDROCEROL® CF 40E as a nucleating agent andHeritage Plastics HT6000 LLDPE talc as another nucleating agent, and CO2or N2 as a blowing agent. The blowing agent was used at levels betweenabout 0.3 lbs/hr to about 1.25 lbs/hour. Ampacet 102823 Process Aid PEMB LLDPE was added as a slip agent and COLORTECH® 11933-19 was added asa colorant. In some examples, DOW® AFFINITY™ PL 1880G polyolefinelastomer was added as an impact modifier to the formulation. Thevarious formulations and resulting multi-layer parison and insulativecontainer densities are shown below in Table 2.

TABLE 2 Comparison of different insulative cellular non-aromaticpolymeric material formulations to create various multi-layer parisonand insulative container densities Base Base Bottle Parison Resin ResinAdditive Additive Additive Additive Gas Density Density Trial #1 #2 #1#2 #3 #4 [lbs/hr] [g/cm³] [g/cm³] 9.1 47.5% 47.5% LBI 1.5% 2% 1% 0.5%0.09 0.649 0.423 Formosa CF-40E Ampacet Colortech HT4HP N₂ 9.2 24.975%74.925% 0.1% 0.03 0.906 0.771 Formosa LBI CF-40E N₂ 0.25MI 9.3 24.6875%74.0625% 0.75% 0.5% 0.1 N₂ 0.668 0.611 Formosa LBI CF-40E HT6000 0.25MI9.4 23.875% 71.625% 2% CF- 2.5% 0.125 0.851 0.720 Formosa LBI 40E HT6000N₂ 0.25MI 9.5 49.7% 49.7% LBI 0.1% 0.5% 0.125 0.668 0.436 Formosa 0.25MICF-40E HT6000 N₂ 9.6 48.375% 48.375% 0.75% 2.5% 0.03 0.903 0.711 FormosaLBI CF-40E HT6000 N₂ 0.25MI 9.7 49% 49% LBI 2% CF- 0.1 N₂ 0.626 0.425Formosa 0.25MI 40E 9.8 73.05% 24.35% 0.1% 2.5% 0.1 N₂ 0.751 0.495Formosa LBI CF-40E HT6000 0.25MI 9.9 74.4375% 24.8125% 0.75% 0.125 0.5780.422 Formosa LBI CF-40E N₂ 0.25MI 9.10 73.125% 24.375% 2% CF- 0.5% 0.030.858 0.566 Formosa LBI 40E HT6000 N₂ 0.25MI 9.11 42.25% 42.25% 15% 0.1%CF- 0.4% 0.125 0.640 0.441 Formosa LBI Dow 40E HT6000 N₂ 0.25MI ImpactMod 9.12 42.25% 42.25% 15% 0.1% CF- 0.4% 0.1 N₂ 0.742 0.502 Formosa LBIDow 40E HT6000 0.25MI Impact Mod 9.13 42.25% 42.25% 15% 0.1% CF- 0.4%0.1 N₂ 0.735 0.508 Formosa LBI Dow 40E HT6000 0.25MI Impact Mod 9.1442.25% 42.25% 15% 0.1% CF- 0.4% 0.1 N₂ 0.766 0.512 Formosa LBI Dow 40EHT6000 0.25MI Impact Mod

Example 10 Formulations and Test Results

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer was used aspolyethylene base resin. The polyethylene base resin was used in variouspercentages from about 97.95% to about 100% of the formulation. In someexamples, the polyethylene base resin was blended with HYDROCEROL® CF40E as a nucleating agent and Heritage Plastics HT6000 LLDPE talc asanother nucleating agent, and N2 as a blowing agent. The blowing agentwas used at levels between about 0.05 lbs/hr to about 0.15 lbs/hour.COLORTECH® 11933-19 was added as a colorant in some examples. Thevarious formulations and resulting multi-layer parison and insulativecontainer densities are shown below in Table 3.

TABLE 3 Comparison of different insulative cellular non-aromaticpolymeric material formulations to create various multi-layer parisonand insulative container densities Formosa N₂ Bottle Density ParisonDensity Trial 5502F Colortech CF-40E HT6000 [lbs/hr] [g/cm³] [g/cm³]10.1 97.95%  1% 0.75%  0.3% 0.1222 0.7183 * 10.2   98% 0%   2%   0%0.0529 0.6950 * 10.3 99.25%  0% 0.75%    0% 0.0534 0.7296 * 10.4   99%0% 1.0%   0% 0.0511 0.7404 0.4292 10.5 98.7% 0% 1.0% 0.3% 0.0514 0.73160.4272 10.6 98.45%  0% 1.25%  0.3% 0.0521 0.7309 0.4276 10.7 98.75%  0%1.25%    0% 0.0529 0.7303 0.4236 10.8 98.75%  0% 1.25%    0% 0.05220.7136 0.4234 10.9 98.75%  0% 1.25%    0% 0.0538 0.7214 0.4304 10.10 100% 0%   0%   0% 0.1468 * * 10.11  100% 0%   0%   0% 0.1392 * * 10.1299.9% 0%   0% 0.1% 0.1393 * * 10.13 99.5% 0%   0% 0.5% 0.0656 * * 10.1499.4% 0% 0.1% 0.5% 0.0702 * * 10.15 99.3% 0% 0.2% 0.5% 0.0692 * * 10.1699.7% 0% 0.1% 0.2% 0.0673 * * 10.17 99.7% 0% 0.1% 0.2% 0.0892 * * 10.1899.7% 0% 0.1% 0.2% 0.105 * * 10.19 99.7% 0% 0.1% 0.2% 0.1188 * * 10.2099.7% 0% 0.1% 0.2% 0.0915 * * 10.21 99.05%  0% 0.75%  0.2% 0.0906 * * *Data not available

Example 11 Formulations and Test Results

Bottles were formed from 99.4 wt % FORMOSA PLASTICS® FORMOLENE® HB5502FHDPE hexene copolymer as the polyethylene base resin blended with 0.1 wt% HYDROCEROL® CF 40E as a nucleating agent and 0.5 wt % HeritagePlastics HT6000 LLDPE talc as another nucleating agent with 0.04 lbs/hrof N₂ blowing agent. The resulting bottles and parisons were a singlelayer (i.e., monolayer). The resulting monolayer parison and monolayercontainer densities are shown under the various process conditions.

TABLE 4 Comparison of process parameters on bottle and parisondensities. Run Cycle Parison ρ Bottle ρ [#] [s] Air [psi] Vacuum (g/cm³)(g/cm³) 1 14 40 Off 0.546 0.748 2 14 40 On 0.570 0.795 3 14 60 Off 0.5420.706 4 14 60 On 0.538 0.724 5 15 40 Off 0.553 0.792 6 15 40 On 0.5590.789 7 15 60 Off 0.542 0.844 8 15 60 On 0.550 0.798 9 16 40 Off 0.5360.649 10 16 40 On 0.549 0.788 11 16 60 Off 0.540 0.825 12 16 60 On 0.5550.840 13 17 40 Off 0.548 0.791 14 17 40 On 0.544 0.789 15 17 60 Off0.543 0.716 16 17 60 On 0.548 0.707 17 18 40 Off 0.546 0.806 18 18 40 On0.540 0.792 19 18 60 Off 0.533 0.833 20 18 60 On 0.547 0.829

Example 12 Formulations and Test Results

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer was used aspolyethylene base resin. The polyethylene base resin was used in 99.4 wt% of the formulation. The polyethylene base was either 100% virgin HDPE(i.e., the control) or a combination of virgin HDPE and regrind. Theregrind was a foam bottle produced according to Example 11, ground up,and then put back into the system. The polyethylene base resin wasblended with 0.1 wt % HYDROCEROL® CF 40E as a nucleating agent and 0.5wt % Heritage Plastics HT6000 LLDPE talc as another nucleating agent,and N2 as a blowing agent. The blowing agent was used at about 0.04lbs/hr. The various formulations and resulting monolayer parison andinsulative container densities are shown below in Table 5.

TABLE 5 Comparison of percent virgin and percent regrind on bottle andparison densities. Cycle Parison ρ Bottle ρ Run [#] Virgin Regrind Time(g/cm³) (g/cm³) Control 100% 0% 15 0.617 0.757 1 80% 20% 14 0.524 0.7692 80% 20% 15 0.493 0.728 3 80% 20% 16 0.499 0.747 4 60% 40% 14 0.5190.747 5 60% 40% 15 0.531 0.751 6 60% 40% 16 0.523 0.742 7 40% 60% 140.493 0.718 8 40% 60% 15 0.435 0.697 9 40% 60% 16 0.444 0.682 10 20% 80%14 0.442 0.690 11 20% 80% 15 0.483 0.726 12 20% 80% 16 0.493 0.728The bottles produced with regrind as part of the base polyethylenemaintained densities of about 80%.

In another set of bottles produced as described immediately above exceptthat the regrind was a 2nd pass regrind.

TABLE 6 Comparison of percent virgin and percent 2nd pass regrind onbottle and parison densities. Cycle Parison ρ Bottle ρ Run [#] VirginRegrind Time (g/cm³) (g/cm³) 1 80% 20% 14 0.536 0.773 2 80% 20% 15 0.5020.764 3 80% 20% 16 0.496 0.778

Even with 2nd pass regrind, bottle characteristics were very similar tothe characteristics of bottles produced with virgin HDPE.

Example 13 Effect of RPM on Bottle Formation

FORMOSA PLASTICS® FORMOLENE® HB5502F HDPE hexene copolymer was used aspolyethylene base resin, at about 99.4%. The polyethylene base resin wasblended with 0.1% HYDROCEROL® CF 40E as a nucleating agent and HeritagePlastics HT6000 LLDPE talc as another nucleating agent, and N2 as ablowing agent. The blowing agent was used at about 0.04 lbs/hr. Thisformulation was processed at various RPMs to produce bottles. Thus, theonly variable in the bottle formation of these different runs was theRPMs of the throughput system.

TABLE 7 Effect of RPMs on Drop Test results. Parison Drop Run ρ Bottle ρWeight Top Test [#] RPM (g/cm3) (g/cm3) (g) Thickness Load [Pass] 5 480.711 0.892 54.5 41.2 87.562 100% 1 36 0.660 0.842 50.2 37.7 92.696 100%1A 36 0.638 0.780 51.5 43.6 89.578 100% 2 27 0.577 0.817 53.4 42.1105.806 100% 3 18 0.495 0.756 45.0 37.0 73.94 20% 4 11 0.396 0.601 32.030.7 36.764 0%

Changing the RPM in the throughput system produced changes to bottle andparison characteristics. For example, higher RPMs produced a higherdensity parison and higher density bottle. Thereby, using a lower RPM inthe throughput system produced lower density bottles. Although thesesystems utilized a single drop, this shows that a multi-parison dropsystem is possible. For example, a throughput system can start at aparticular RPM (e.g., 48 RPM) for the extrusion stream and then and thensplit into multiple parison streams at lower RPMs. In an illustrativeexample, one extrusion stream can start at 48 RPM and split into 4parison drop streams running at 12 RPM. This would produce a moreefficient foaming system to produce bottles.

Example 14 Density Measurements

This Example demonstrates the test used to measure the density of filledand unfilled polymer parts.

Procedure

The density was determined by the apparatus shown, unassembled, in FIG.2. Although not shown in FIG. 2, the apparatus also included athermometer to measure the suspension liquid temperature. A suspensionliquid is a fluid with a density lower than that of the sample to bemeasured. The sample must sink in the suspension fluid to determine thesample density. Water has a density of 1 g/cm3, so most unfilledpolymers require some other suspension fluid such as isopropyl alcohol,density=0.8808 g/cm3. A Mettler AT400 balance (Mettler-Toledo LLC,Columbus, Ohio) was also used.

The density of a limestone-filled HDPE bottle was measured. After taringthe balance to zero, the dry solid sample was weighed after placing itin the cup of the Mettler balance. The dry weight was 0.3833 g. Afterweighing the dry sample and before removing the sample from the cup, thebalance was tared again. The sample was removed from the cup and placedon the gem holder in the suspension fluid. The sample was weighedproviding the weight with a negative number (−0.3287 g). The number wasconverted to its absolute value (0.3287 g); the positive value is thesample buoyancy. The sample density was calculated by multiplying thedry weight (0.3833 g) by the sample buoyancy (0.3287 g) by thesuspension fluid density (0.8808 g/cc), which equaled 1.0272 g/cc.

Example 15 Formulations and Test Results

Marlex® HHM 5502BN HDPE hexene copolymer (Chevron Phillips ChemicalCompany, The Woodlands, Tex.) was used as polyethylene base resin in thecore layer. The polyethylene base resin was used in various percentagesfrom about 98% to about 100% of the formulation. In some examples, thepolyethylene base resin was blended with HYDROCEROL® CF 40E as achemical blowing agent in all non-control samples and Heritage PlasticsHT4HP talc as another nucleating agent, and N2 as a blowing agent. Theblowing agent was used at about 11 kg/hr. The various formulations andresulting multi-layer parison and insulative container densities areshown below in Table 3.

The extruded material was a multi-layer material where the core layerwas sandwiched between an outer and inner polymeric layer. The outer andinner layer were comprised of various amounts of Marlex® HHM 5502BN HDPEhexene copolymer (Chevron Phillips). The outer polymeric layer alsoincluded 5 wt % colorant (COLORTECH® 11933-19 titanium oxide). The innerpolymeric layer did not include a colorant. Some embodiments of theformulations included inner and/or outer polymeric layers comprising areinforcing fiber (Hyperform® HPR-803i, Milliken & Co., Spartanburg,S.C.).

TABLE 8 Comparison of different insulative cellular non-aromaticpolymeric material formulations to create various multi-layer parisonand insulative container densities Core Layer Outer Layer Inner LayerSample HDPE CBA Talc HDPE Color Fiber HDPE Fiber Control  100%   0%   0%95% 5% 0% 100% 0% 1-1  100% 0.10% 0.30% 95% 5% 0% 100% 0% 1-2  100%0.10% 0.30% 95% 5% 0% 100% 0% 1-3  100% 0.10% 0.30% 95% 5% 0% 100% 0%1-4 98.4% 0.10% 1.50% 95% 5% 0% 100% 0% 1-5 98.4% 0.10% 1.50% 95% 5% 0%100% 0% 1-6 98.4% 0.10% 1.50% 95% 5% 0% 100% 0% 1-7 99.2% 0.50% 0.30%95% 5% 0% 100% 0% 1-8 99.2% 0.50% 0.30% 95% 5% 0% 100% 0% 1-9 99.2%0.50% 0.30% 95% 5% 0% 100% 0% 1-10 98.0% 0.50% 1.50% 95% 5% 0% 100% 0%1-10A 98.0% 0.50% 1.50% 80% 5% 15% 85% 15% 1-11 98.0% 0.50% 1.50% 95% 5%0% 100% 0% 1-12 98.0% 0.50% 1.50% 95% 5% 0% 100% 0% 1-13 99.6% 0.10%0.30% 85% 5% 10% 100% 0% 1-14 99.6% 0.10% 0.30% 80% 5% 15% 100% 0% 1-1599.6% 0.10% 0.30% 75% 5% 20% 100% 0%

TABLE 9 Effect of formulation on Physical Characteristics, Bottle andParison Density, and Performance Bottle ρ Parison ρ Weight Density WaterDrop Sample (g/cm³) (g/cm³) (g) (g/cm³) (% passed test) Control 23.00.934 100% 1-1 0.58 0.46 17.1 0.710 70% 1-2 0.655 0.46 16.9 0.734 80%1-3 0.79 0.46 17.1 0.760 70% 1-4 0.58 0.45 17.7 0.644 90% 1-5 0.70 0.4517.2 0.685 100% 1-6 0.80 0.45 16.8 0.744 80% 1-7 0.60 0.5 17.4 0.612 60%1-8 0.69 0.5 17.3 0.697 100% 1-9 0.74 0.5 17.1 0.760 100% 1-10 0.61 17.00.625 100% 1-10A 0.47 17.0 0.479 60% 1-11 0.67 17.1 0.693 100% 1-12 0.8217.5 0.784 100% 1-13 0.61 17.0 0.624 100% 1-14 0.67 17.5 0.656 90% 1-150.62 17.1 0.665 90%

The invention claimed is:
 1. A formulation comprising (a) at least onehigh density polyethylene (HDPE) base resin, (b) a chemical blowingagent which is up to about 2 wt % of the formulation, (c) a physicalblowing agent, (d) a nucleating agent which is up to about 15 wt % ofthe formulation, (e) a slip agent which is up to about 3 wt % of theformulation, and (f) a colorant which is up to about 4 wt % of theformulation, wherein the formulation has a density of about 0.4 g/cm³ toabout 0.9 g/cm³, the HDPE base resin is about 50 wt % to about 99.9 wt %of the formulation, and the formulation is non-aromatic.
 2. Theformulation of claim 1, wherein the HDPE is a high melt strength HDPE.3. The formulation of claim 1, wherein the HDPE is long-chain branchingHDPE.
 4. The formulation of claim 1, wherein the HDPE is a hexenecopolymer.
 5. The formulation of claim 4, wherein the HDPE base resin isabout 85 wt % to about 99.9 wt % of the formulation.
 6. The formulationof claim 5, wherein the HDPE base resin is about 10% to about 100%virgin HDPE.
 7. The formulation of claim 1, wherein the chemical blowingagent is about 0.1 wt % to about 2 wt % of the formulation.
 8. Theformulation of claim 1, wherein the nucleating agent is selected fromthe group consisting of talc, CaCO₃, mica, and mixtures of at least twoof the foregoing.
 9. The formulation of claim 1, wherein the nucleatingagent is about 0.1 wt % to about 7 wt % of the formulation.
 10. Theformulation of claim 9, wherein the formulation lacks talc.
 11. Theformulation of claim 1, wherein the base resin is 100% virgin HDPE. 12.The formulation of claim 1, wherein the HDPE base resin comprises afirst HDPE base resin that comprises 100% virgin HDPE and a second HDPEbase resin that comprises regrind.
 13. A formulation comprising at leastone high density polyethylene (HDPE) base resin, a chemical blowingagent, a physical blowing agent, a nucleating agent, a slip agent, and acolorant, wherein (a) the HDPE base resin is about 80 wt % to about 99.9wt % of the formulation, (b) the chemical blowing agent is up to about 2wt % of the formulation, (c) the nucleating agent is up to about 15 wt %of the formulation, (d) the slip agent is up to about 3 wt % of theformulation, (e) the colorant is up to about 4 wt % of the formulation,and wherein the formulation has a density of about 0.4 g/cm³ to about0.9 g/cm³, and wherein the formulation is non-aromatic.
 14. Theformulation of claim 13, wherein (a) the HDPE is about 95 wt % of theformulation, (b) the chemical blowing agent is about 1.5 wt % of theformulation, (c) the nucleating agent is about 0.5 wt % of theformulation, (d) the slip agent is about 2 wt % of the formulation, and(e) the colorant is about 1 wt % of the formulation.
 15. The formulationof claim 1, wherein the formulation has a density of about 0.5 g/cm³ toabout 0.75 g/cm³.
 16. The formulation of claim 1, wherein the physicalblowing agent is selected from the group consisting of N₂, CO₂, helium,argon, and air.
 17. The formulation of claim 1, wherein the physicalblowing agent is N₂ or CO₂.
 18. The formulation of claim 1, wherein thephysical blowing agent is introduced to the formulation as asupercritical fluid.
 19. The formulation of claim 17, wherein thephysical blowing agent is introduced to the formulation as asupercritical fluid.
 20. The formulation of claim 1, wherein thephysical blowing agent is introduced to the formulation at a rate ofabout 0.02 pounds per hour to about 1.3 pounds per hour.
 21. Theformulation of claim 1, wherein the physical blowing agent is introducedto the formulation at a rate of about 0.05 pounds per hour to about 0.15pounds per hour.
 22. The formulation of claim 19, wherein the physicalblowing agent is introduced to the formulation at a rate of about 0.05pounds per hour to about 0.15 pounds per hour.
 23. The formulation ofclaim 1, wherein the HDPE base resin is about 92 wt % to about 99.9 wt %of the formulation.
 24. A formulation comprising (a) at least one highdensity polyethylene (HDPE) base resin, (b) a chemical blowing agentwhich is up to about 2 wt % of the formulation, (c) a physical blowingagent, (d) a nucleating agent which is up to about 15 wt % of theformulation, and (e) a slip agent which is up to about 3 wt % of theformulation, wherein the formulation has a density of about 0.4 g/cm³ toabout 0.9 g/cm³, and the HDPE base resin is about 92 wt % to about 99.9wt % of the formulation.